FILE: 091-106-150-XX-120
DATE: 10-2-2009
REV: A
INSTRUCTION MANUAL
INDUSTRIAL CHARGER
AUTOMATIC BATTERY CHARGER
SERIES 150
MODEL # 091-106-150-XX-120
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826
INTRODUCTION
The Auto Charge 150 Series of chargers are precise float chargers packaged in a
powder coated steel industrial enclosure which utilizes control concepts and
circuitry proven over many years and tens of thousands of installations in fire trucks,
ambulances, and emergency vehicles. The charger is designed to be connected to
the battery to continuously charge the battery, pick up any electrical loads and by
precise voltage control, assure that the battery is not overcharged.
SYSTEM DESCRIPTION
The charger contains a power transformer, control circuit assembly, SCR rectifier,
current sensing resistor, and ammeter. The Power transformer lowers the A.C. Input
Line Voltage to the level as required by the particular model. The transformer
secondary is applied to the rectifier assembly in which the A.C. Voltage is rectified
in D.C. Voltage to charge the battery. A block diagram appears in Figure 1.
The rectifier assembly contains 2 diodes and 2 silicon controlled rectifiers. Voltage
control of the rectifier assembly is obtained by varying the trigger angle at which the
SCR's are fired. Delaying the trigger angle decreases the voltage while advancing
it increases the voltage.
The control circuit board contains circuits which detect the charger output voltage,
compare it to a precise reference voltage to generate an error signal. This error
signal is amplified and converted to a variable phase signal to trigger the output
SCR's. Charger output current is detected with a current sense resistor. The current
sense signal is used to over-ride the voltage commands to limit the maximum
charger output to its' rated value. This protects the charger when recharging a
deeply discharged battery or when a load in excess of the charger's current rating
is applied to the battery. The current signal is also utilized in the Auto-Equalize
circuit. When recharging a battery composed of a number of cells in series, it is
important to fully charge each of the cells. This is accomplished by raising the
charger output voltage. Many chargers have a Float/Equalize switch. In the float
position the output voltage is the desired battery float voltage. When the switch is
placed in the equalize position, the output voltage is raised 8 to 10%. After
recharging at the equalize voltage for a period of time an operator must manually
switch back to the float position. If this is not done and the battery is held at the
equalize level for a period of time, there is danger of water boil-off. Other
chargers contain a timer which permits the operator to select the time period for
which equalize charging will occur.
The Auto-Equalize circuit as incorporated in the Auto Charge's controller solves
the equalize problem. Whenever the charger output is limited by the current limit
circuits, a signal is fed back to increase the voltage setpoint. The charger is then in
the equalize mode. As the battery is charged up to the equalize voltage, the output
current starts to decrease. When this occurs, the voltage set-point is reset to the
float voltage and the battery is maintained at the float level.
O
FUSE
A.C.
MAINS
TRANSFORMER
SCR
RECTIFIERS
UTPUT
CURRENT
SENSE RESISTOR
CHARGER
L
A
N
G
I
S
L
O
R
T
N
O
C
AMMETER
CURRENT SIGNAL INPUT
CONTROL BOARD
Figure 1
Block Diagram, Auto Charge
With Isolation Transformer
VOLTAGE SIGNAL
INPUT
INSTALLATION & WIRING DIAGRAM
A
Mount the charger in a suitable location to provide adequate air to the ventilation
inlet and outlet. In the float charge state very little heat is generated by the charger.
Under high output current condition, however, the rectifier becomes warm. If this
continues for a sufficient time a thermostatic switch will turn on the fan.
CONTROL P.C.BOARD
TRANSFORMER
Battery
+
D.C. OUTPUT
-
+
5 AMP
INPUT REQ’D:
120 VAC, 50/60 Hz, 2.6 AMPS
Line
G
NL
Neutral
.C. INPUT
5 AMP
Gnd
-
SPECIFICATIONS
MECHANICAL:
Enclosure: 18AWG Steel, Powder Coated
Cooling: Convection, Screen Inlet and Outlet
Size: 13.62 x 9.62 x 6.0 Inches
Weight: 40 Lbs.
Ambient Temperature: -40 to +132 Deg. F
ELECTRICAL:
Model Number Input Power Input Fuse Output Charge Indicator
091-106-150-6-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 6 VDC, 12 Amps 15 Ampere
091-106-150-12-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 12 VDC, 12 Amps 15 Ampere
091-106-150-24-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 24 VDC, 6 Amps 15 Ampere
091-106-150-32-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 32 VDC, 5 Amps 15 Ampere
091-106-150-36-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 36 VDC, 4 Amps 15 Ampere
091-106-150-48-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 48 VDC, 3 Amps 15 Ampere
091-106-150-60-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 60 VDC, 2 Amps 15 Ampere
091-106-150-72-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 72 VDC, 1.5 Amps 15 Ampere
091-106-150-120-120 120 VAC, 50/60 Hz, 2.6 Amps 5 Amp 120 VDC, 1 Amps 15 Ampere
Outline Drawing
INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
WARRANTY
All products of Kussmaul Electronics Company Inc. are warranted to be
free of defects of material or workmanship. Liability is limited to repairing or
replacing at our factory, without charge, any material or defects which
become apparent in normal use within 3 years from the date the equipment
was shipped. Equipment is to be returned, shipping charges prepaid and will
be returned, after repair, shipping charges paid.
Kussmaul Electronics Company, Inc. shall have no liability for damages
of any kind to associated equipment arising from the installation and /or use
of the Kussmaul Electronics Company, Inc. products. The purchaser, by the
acceptance of the equipment, assumes all liability for any damages which
may result from its installation, use or misuse, by the purchaser, his or its
employees or others.
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